EP1116287B1 - Positives kompositelektrodenmaterial und verfahren zu dessen herstellung - Google Patents

Positives kompositelektrodenmaterial und verfahren zu dessen herstellung Download PDF

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Publication number
EP1116287B1
EP1116287B1 EP99939133.7A EP99939133A EP1116287B1 EP 1116287 B1 EP1116287 B1 EP 1116287B1 EP 99939133 A EP99939133 A EP 99939133A EP 1116287 B1 EP1116287 B1 EP 1116287B1
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Prior art keywords
positive electrode
nickel
nickel hydroxide
particles
electrode material
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French (fr)
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EP1116287A4 (de
EP1116287A1 (de
Inventor
Michael A. Fetcenko
Cristian Fierro
Stanford R. Ovshinsky
Beth Sommers
Benjamin Reichman
Kwo Young
William Mays
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Ovonic Battery Co Inc
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Ovonic Battery Co Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1395—Processes of manufacture of electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H01M4/626—Metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/24—Electrodes for alkaline accumulators
    • H01M4/32—Nickel oxide or hydroxide electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
    • H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H01M4/625—Carbon or graphite
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the instant invention relates generally to positive electrode materials for rechargeable batteries such as nickel hydroxide materials. More specifically, the instant invention relates to composite nickel hydroxide particulate having increased conductivity over the prior art material.
  • Rechargeable alkaline cells In rechargeable alkaline cells, weight and portability are important considerations. It is also advantageous for rechargeable alkaline cells to have long operating lives without the necessity of periodic maintenance.
  • Rechargeable alkaline cells are used in numerous consumer devices such as calculators, portable radios, and cellular phones. They are often configured into a sealed power pack that is designed as an integral part of a specific device. Rechargeable alkaline cells can also be configured as larger cells that can be used, for example, in industrial, aerospace, and electric vehicle applications.
  • NiCd nickel cadmium
  • Ni-MH nickel metal hydride
  • nickel hydrogen nickel zinc
  • nickel iron cells nickel iron cells
  • NiCd rechargeable alkaline cells are the most widely used although it appears that they will be replaced by Ni-MH cells.
  • Ni-MH cells made of synthetically engineered materials have superior performance parameters and contain no toxic elements.
  • Ni-MH cells utilize a negative electrode that is capable of the reversible electrochemical storage of hydrogen.
  • Ni-MH cells usually employ a positive electrode of nickel hydroxide material. The negative and positive electrodes are spaced apart in the alkaline electrolyte. Upon application of an electrical potential across a Ni-MH cell, the Ni-MH material of the negative electrode is charged by the electrochemical absorption of hydrogen and the electrochemical discharge- of a hydroxyl ion, as shown in equation (1):
  • Ni-MH materials are discussed in detail in U.S. Patent No. 5,277,999 to Ovshinsky, et al .
  • the discharge capacity of a nickel based positive electrode is limited by the amount of active material, and the charging efficiencies.
  • the charge capacities of a Cd negative electrode and a MH negative electrode are both provided in excess, to maintain the optimum capacity and provide overcharge protection.
  • a goal in making the nickel positive electrode is to obtain as high an energy density as possible.
  • the volume of a nickel hydroxide positive electrode is sometimes more important than weight. The volumetric capacity density is usually measured in mAh/cc and specific capacity is written as mAh/g.
  • NiCd and Ni-MH cells sintered or pasted nickel hydroxide positive electrodes are used in NiCd and Ni-MH cells.
  • the process of making sintered electrodes is well known in the art.
  • Conventional sintered electrodes normally have an energy density of around 480-500 mAh/cc. In order to achieve significantly higher capacity, the current trend has been away from sintered positive electrodes and toward foamed and pasted electrodes.
  • Sintered nickel electrodes have been the dominant nickel electrode technology for several decades for most applications. These consist of a porous nickel plaque of sintered high surface area nickel particles impregnated with nickel hydroxide active material either by chemical or electrochemical methods. While expensive, sintered electrodes provide high power, high reliability, and high cycle life, but not the highest energy density. They are likely to remain important for high reliability military and aerospace applications for some time.
  • Pasted nickel electrodes consist of nickel hydroxide particles in contact with a conductive network or substrate, preferably having a high surface area.
  • these electrodes including the so-called plastic-bonded nickel electrodes which utilize graphite as a microconductor and also including the so-called foam-metal electrodes which utilize high porosity nickel foam as a substrate loaded with spherical nickel hydroxide particles and cobalt conductivity enhancing additives.
  • Pasted electrodes of the foam-metal type now dominate the consumer market due to their low cost, simple manufacturing, and higher energy density relative to sintered nickel electrodes.
  • the nickel battery electrode reaction has been considered to be a one electron process involving oxidation of divalent nickel hydroxide to trivalent nickel oxyhydroxide on charge and subsequent discharge of trivalent nickel oxyhydroxide to divalent nickel hydroxide, as shown in equation 2 hereinbelow.
  • nickel hydroxide positive electrode material in its most basic form has a maximum theoretical specific capacity of 289 mAh/g, when one charge/discharge cycles from a ⁇ II phase to a ⁇ III phase and results in one electron transferred per nickel atom. It was recognized in the prior art that greater than one electron transfer could be realized by deviating from the ⁇ II and ⁇ III limitations and cycling between a highly oxidized ⁇ -phase nickel hydroxide phase and the ⁇ II phase. However, it was also widely recognized that such gamma phase nickel hydroxide formation destroyed reversible structural stability and therefore cycle life was unacceptably degraded. A large number of patents and technical literature disclosed modifications to nickel hydroxide material designed to inhibit and/or prevent the destructive formation of the transition to the ⁇ -phase, even though the higher attainable capacity through the use of ⁇ -phase is lost.
  • NiCoCd NiCoZn
  • NiCoMg NiCoMg
  • U.S. Patent No. 5,451,475, to Ohta, et al., issued 19 September 1995 describes the positive nickel hydroxide electrode material as fabricated with at least one of the following elements added to the surface of the particles thereof: cobalt, cobalt hydroxide, cobalt oxide, carbon powder, and at least one powdery compound of Ca, Sr, Ba, Cu, Ag, and Y.
  • the cobalt, cobalt compound, and carbon are described as constituents of a conductive network to improve charging efficiency and conductivity.
  • the powdery compound is described as adsorbed to the surface of the nickel hydroxide active material where it increases the overvoltage, for evolution of oxygen, thereby increasing nickel hydroxide utilization at high temperature.
  • Ohta, et al. claims that increased utilization in NiMH cells using the disclosed invention remains constant up to a high number of charge/discharge cycles and utilization does not drop as much at higher temperatures as it does in cells that do not embody the invention.
  • U.S. Patent No. 5,455,125 to Matsumoto, et al., issued 3 October 1995 describes a battery having a positive electrode comprising nickel hydroxide pasted on a nickel foam substrate with solid solution regions of Co and salts of Cd, Zn, Ca, Ag, Mn, Sr, V, Ba, Sb, Y, and rare earth elements.
  • the addition of the solid solution regions is intended to control the oxygen overvoltage during charging.
  • the further external addition of "electric conducting agents” such as powdered cobalt, cobalt oxide, nickel, graphite, "and the like," is also described.
  • Energy density is shown as constant at 72 Wh/kg at 20°C and 56 Wh/kg at 45°C for embodiments of the invention over the life of the NiMH cell.
  • U.S. Patent No. 5,466,543, to Ikoma, et al., issued 14 November 1995 describes batteries having improved nickel hydroxide utilization over a wide temperature range and increased oxygen overvoltage resulting from the incorporation of at least one compound of yttrium, indium, antimony, barium, or beryllium, and at least one compound of cobalt or calcium into the positive electrode.
  • Cobalt hydroxide, calcium oxide, calcium hydroxide, calcium fluoride, calcium peroxide, and calcium silicate are specifically described compounds. Additionally described additives are cobalt, powdery carbon, and nickel.
  • the specification particularly describes AA cells using a positive electrode containing 3 wt% zinc oxide and 3 wt% calcium hydroxide as superior in terms of cycle life (250 cycles at 0°C, 370 cycles at 20°C, and 360 cycles at 40°C) and discharge capacity (950 mAh at 20°C, 850 mAh at 40°C, and 780 mAh at 50°C).
  • the basic nickel hydroxide material is treated, most commonly, by the addition of a single element, usually Co compounds, to increase electrical conductivity and usually one other element, usually Cd or Zn, to suppress and/or prevent ⁇ -phase formation.
  • a single element usually Co compounds
  • one other element usually Cd or Zn
  • Ni-MH batteries have achieved impressive gains in high rate discharge performance.
  • hybrid electric vehicles has demanded that Ni-MH batteries achieve 1000 W/kg of power.
  • Conventional electric vehicle batteries achieve 250 W/kg and special designs achieve 500-600 W/kg.
  • NiCo co-precipitates have better conductivity and utilization than pure nickel hydroxide, the improvement can only be considered incremental with no room for further improvement.
  • Document JP 60253156 describes a conventional Nickel positive electrode for alkaline battery and its manufacturing method, wherein formation and aggregation of particles of active material are produced with inclusion of metallic particle inside vacancies created during aggregation of the particles.
  • An objective of the present invention is to provide a positive electrode having increased conductivity, according to claim 1. This and other objectives are satisfied by a composite positive electrode material for use in electrochemical cells.
  • the material comprises a particle of positive electrode material; and a conductive material totally embedded within the particle of positive electrode material.
  • the conductive material may be metallic particles such as nickel particles.
  • a method for producing a composite positive electrode material according to claim 7 comprising a particle of positive electrode material and a conductive material totally embedded within the particle of positive electrode material, the method comprising the step of: combining a metal ion solution, a caustic solution, and a conductive material, whereby a precipitation solution including the composite positive electrode material is formed and precipitation of the positive electrode material onto the metallic conductive material suspended in a precipitation bath.
  • the combining step may comprise the steps of mixing the conductive material with the metal ion solution to form a suspension; and mixing the suspension with the caustic solution.
  • the instant inventors have discovered improvements in positive electrode material for use in electrochemical cells and methods for making the improved materials.
  • a composite positive electrode material for use in electrochemical cells comprises a particle of positive electrode material, and a conductive material which is totally embedded within the particle of positive electrode material.
  • the conductive material is any material which is electrically conductive.
  • the conductive material is chosen so that the conductivity of the composite positive electrode material is greater than the conductivity of the active positive electrode material alone.
  • the conductive material may comprise a metal.
  • metals which may be used include, but are not limited to, nickel, nickel alloys, copper, and copper alloys.
  • the metal is nickel.
  • nickel refers to substantially pure nickel.
  • copper refers to substantially pure copper.
  • nickel has an atomic configuration comprising d-orbitals. While not wishing to be bound by theory, it is believed that the d-orbitals may effect the active positive electrode material surrounding the nickel material.
  • the conductive material may also comprise a material selected from the group consisting of oxides, nitrides, carbides, silicides, and borides.
  • the conductive material may comprise carbon, or graphite.
  • the conductive material may comprise copper oxide, cobalt oxide, or indium tin oxide.
  • the conductive material may be in the form of at least one conductive particle which is totally embedded in the particle of positive electrode material.
  • the conductive particle is metallic. More preferably, the conductive particle is a nickel particle.
  • Figure 1 shows a photomicrograph, at magnification of 10,000x, of an embodiment of the composite material of the present invention.
  • the composite material comprises a particle of positive electrode material 1, and a nickel particle 3 which is totally embedded in the particle of positive electrode material 1.
  • the conductive material may comprise a plurality of conductive particles which are totally embedded within the particle of positive electrode material.
  • the plurality of conductive particles may be isolated from one another. Alternately, at least some of the particles may be touching others so as to form a conductive network of particles.
  • the conductive particles may have a variety of shapes and sizes.
  • the particles may be substantially spherical.
  • the particles may be elongated wherein one dimension is longer than another dimension.
  • the particles may be ellipsoidal or cylindrical.
  • the particles may be in the form of threadlike fibers.
  • These elongated particles may have an average length which is less than or equal to about 10 microns. As well they may have an average diameter of less than or equal to about 1.0 micron. These sizes are merely reference points and may be varied within the scope of the invention.
  • An example of conductive particles are the INCO T-210 nickel particles.
  • the INCO T-210 nickel particles have a particle morphology with an average sub-micron Fisher diameter of about .9 microns, an apparent density of about 6 grams per cm 3 , and a BET of about 1.75 m 2 /g.
  • the conductive material may take the form of a conductive network.
  • the conductive network may have various topologies.
  • One example of a conductive network is a lattice structure which may be formed by the interconnection of conductive particles, fibers, strands, and the like.
  • Another example of a conductive network is the branching tree-like structure that is shown in Figure 2 .
  • the conductive network 3A branches out throughout the active positive electrode particle 1.
  • Another example of a conductive network is one comprising one or more carbon nanotubes and/or fullerenes.
  • the embedded conductive material serves one or both of two possible roles in the composite material.
  • the conductive material serves as an electronically conductive pathway through the active positive electrode material, thereby increasing the useable capacity of the active material.
  • the internal conductive pathway also improves the ionic transport within the active material and prevents portions of the active material from becoming electrically isolated by reducing the transport distance through the active material and/or optimizing alignment of crystallite pathways.
  • NiOOH oxidized nickel oxyhydroxide
  • Ni(OH) 2 highly resistive nickel hydroxide
  • the present invention overcomes such electronic isolation and ionic transport limitations.
  • electronic isolation of the active material is reduced or avoided by providing an electronically conductive pathway in the interior of the nickel hydroxide particles. This allows for added electronic pathways which reduce or prevent isolation of the active material by the more resistive reduced nickel hydroxide material.
  • the second role that the conductive material, such as the nickel particle 3, may play is that of a nucleation site for the growth of nickel hydroxide crystallites.
  • the particles of nickel hydroxide material comprise crystallites, and the nickel particle 3 behaves as a "nucleating particle" (i.e., a nucleation site for the growth of the nickel hydroxide crystallites).
  • the nickel particle 3 may orient the nickel hydroxide crystallites as they deposit onto the nickel particle during precipitation.
  • the nickel particle 3 may also influence the size and/or shape of the nickel hydroxide crystallites.
  • Each nickel hydroxide particle is composed of many very fine crystallites which may have an improved crystallographic orientation within the boundary of the crystallite.
  • the protonic conductivity (i.e., the conductivity of protons) in a typical nickel hydroxide particle is dominated by (1) conduction within crystallites and (2) conduction across the grain boundaries between adjacent crystallites.
  • the crystallite size is too large, the fully discharged nickel hydroxide does not have enough vacancies, created at the grain boundaries for the initial charging current to provide for a proton to hop from one vacancy to another vacancy, and therefore such large crystallites provide for relatively poor conductivity.
  • the crystallite size is too small, the adjacent crystal lattice conduction networks will not be aligned due to the presence of too many grain boundary vacancies for the protons to hop across and protonic conductivity is thereby impeded.
  • the crystallites are believed to require proper orientation to be highly conductive. That is, if there are discontinuities in the crystallite orientation from one crystallite to another then the crystallites that are improperly oriented for lower resistance current flow will dominate the resistance of the material. Conversely, if all of the crystallites are properly oriented, the conductivity of the nickel hydroxide material may be increased. The inventors believe that the nickel particle 3 may preferentially orient the crystallites of nickel hydroxide in this highly conductive orientation as they deposit, such that the nickel hydroxide has a higher protonic conductivity than nickel hydroxide deposited in a random manner.
  • nucleation sites alter the size and/or shape of the crystallites.
  • crystallites would have a spherical shape, while in the present invention the crystallites could have a more elongated shape.
  • protonic conduction is preferential along the 101 axis of the nickel hydroxide.
  • the role of the nucleation sites could be to reduce the distance along the 101 plane to the crystallite boundary or to orient the 101 planes from one crystallite to an other for enhance conduction.
  • the active positive electrode material used in the present invention may be may be any type of positive electrode material known in the art. Examples include nickel hydroxide material and manganese hydroxide material. It is within invention that any and all kinds of nickel hydroxide, or positive materials in general, may be used. Even pure nickel hydroxide without cobalt, a material with poor conductivity for commercial application, may be transformed into a viable positive electrode material via the internally embedded nickel particles or fibers described herein.
  • the nickel hydroxide material may be a disordered material.
  • disordered materials allow for permanent alteration of the properties of the material by engineering the local and intermediate range order. The general principals are discussed in U.S. Patent No. 5,348,822 .
  • the nickel hydroxide material may be compositionally disordered. "Compositionally disordered” as used herein is specifically defined to mean that this material contains at least one compositional modifier and/or a chemical modifier. Also, the nickel hydroxide material may also be structurally disordered.
  • Structurally disordered as used herein is specifically defined to mean that the material has a conductive surface and filamentous regions of higher conductivity, and further, that the material has multiple or mixed phases where alpha, beta, and gamma-phase regions may exist individually or in combination.
  • the nickel hydroxide material may comprise a compositionally and structurally disordered multiphase nickel hydroxide host matrix which includes at least one modifier chosen from the group consisting of Al, Ba, Bi, Ca, Co, Cr, Cu, F, Fe, In, K, La, Li, Mg, Mn, Na, Nd, Pb, Pr, Ru, Sb, Sc, Se, Sn, Sr, Te, Ti, Y, and Zn.
  • at least one modifier chosen from the group consisting of Al, Ba, Bi, Ca, Co, Cr, Cu, F, Fe, In, K, La, Li, Mg, Mn, Na, Nd, Pb, Pr, Ru, Sb, Sc, Se, Sn, Sr, Te, Ti, Y, and Zn.
  • the nickel hydroxide material comprises a compositionally and structurally disordered multiphase nickel hydroxide host matrix which includes at least three modifiers chosen from the group consisting of Al, Ba, Bi, Ca, Co, Cr, Cu, F, Fe, In, K, La, Li, Mg, Mn, Na, Nd, Pb, Pr, Ru, Sb, Sc, Se, Sn, Sr, Te, Ti, Y, and Zn.
  • modifiers chosen from the group consisting of Al, Ba, Bi, Ca, Co, Cr, Cu, F, Fe, In, K, La, Li, Mg, Mn, Na, Nd, Pb, Pr, Ru, Sb, Sc, Se, Sn, Sr, Te, Ti, Y, and Zn.
  • the nickel hydroxide materials may be multiphase polycrystalline materials having at least one gamma-phase that contain compositional modifiers or combinations of compositional and chemical modifiers that promote the multiphase structure and the presence of gamma-phase materials.
  • compositional modifiers are chosen from the group consisting of Al, Bi, Co, Cr, Cu, Fe, In, LaH 3 , Mg, Mn, Ru, Sb, Sn, TiH 2 , TiO, Zn.
  • at least three compositional modifiers are used.
  • the nickel hydroxide materials may include the non-substitutional incorporation of at least one chemical modifier around the plates of the material.
  • the phrase "non-substitutional incorporation around the plates", as used herein means the incorporation into interlamellar sites or at edges of plates.
  • chemical modifiers are preferably chosen from the group consisting of Al, Ba, Ca, Co, Cr, Cu, F, Fe, K, Li, Mg, Mn, Na, Sr, and Zn.
  • the nickel hydroxide materials do not have distinct oxidation states such as 2 + , 3 + , or 4 + . Rather, these materials form graded systems that pass 1.0 to 1.7 and higher electrons.
  • the nickel hydroxide material may comprise a solid solution nickel hydroxide material having a multiphase structure that comprises at least one polycrystalline gamma-phase including a polycrystalline gamma-phase unit cell comprising spacedly disposed plates with at least one chemical modifier incorporated around said plates, said plates having a range of stable intersheet distances corresponding to a 2 + oxidation state and a 3.5 + , or greater, oxidation state; and at least three compositional modifiers incorporated into the solid solution nickel hydroxide material to promote the multiphase structure.
  • This embodiment is fully described in commonly assigned U.S. Patent No. 5,348,822 .
  • one of the chemical modifiers is chosen from the group consisting of Al, Ba, Ca, Co, Cr, Cu, F, Fe, K, Li, Mg, Mn, Na, Sr, and Zn.
  • the compositional modifiers may be chosen from the group consisting of a metal, a metallic oxide, a metallic oxide alloy, a metal hydride, and a metal hydride alloy.
  • the compositional modifiers are chosen from the group consisting of Al, Bi, Co, Cr, Cu, Fe, In, LaH 3 , Mn, Ru, Sb, Sn, TiH 2 , TiO, and Zn.
  • one of the compositional modifiers is chosen from the group consisting of Al, Bi, Co, Cr, Cu, Fe, In, LaH 3 , Mn, Ru, Sb, Sn, TiH 2 , TiO, and Zn.
  • one of the compositional modifiers is Co.
  • two of the compositional modifiers are Co and Zn.
  • the nickel hydroxide material may contain 5 to 30 atomic percent, and preferable 10 to 20 atomic percent, of the compositional or chemical modifiers described above.
  • the disordered nickel hydroxide electrode materials may include at least one structure selected from the group consisting of (i) amorphous; (ii) microcrystalline; (iii) polycrystalline lacking long range compositional order; and (iv) any combination of these amorphous, microcrystalline, or polycrystalline structures.
  • a general concept of the present invention is that a disordered active material can more effectively accomplish the objectives of multi-electron transfer, stability on cycling, low swelling, and wide operating temperature than prior art modifications.
  • the nickel hydroxide material may be a structurally disordered material comprising multiple or mixed phases where alpha, beta, and gamma-phase region may exist individually or in combination and where the nickel hydroxide has a conductive surface and filamentous regions of higher conductivity.
  • electrolytes where the electrolyte comprises at least one element chosen from the group consisting of Ba, Ca, Cs, K, Li, Na, Ra, Rb, and Sr, combined with at least one member of the group consisting of Br, Cl, F, OH.
  • electrolytes are formulations of KOH, NaOH, LiOH and/or CsF, and KOH and CsOH.
  • Also disclosed herein is a method for producing a composite positive electrode material comprising a particle of positive electrode material, and a conductive material totally within the particle of positive electrode material.
  • the general method for making the composite material is by precipitation of a positive electrode material (such as the nickel hydroxide material) onto the conductive material suspended in a precipitation bath.
  • the specific method can be varied widely, as will be described hereinbelow, as long as the positive electrode material is deposited onto the conductive material.
  • the method requires a source of metal ion solution, a source of the conductive material, and a source of caustic (sodium hydroxide) be provided.
  • the method comprises the step of combining the metal ion solution, the caustic solution and the conductive material so that a precipitation solution which includes the composite positive electrode material is formed.
  • a major proportion of the metal ion solution should include the active materials main metal ion, for instance nickel ions, for deposition of a nickel hydroxide material. While nickel ions are typically used, manganese ions (for deposition of a manganese hydroxide solution) may also be used. Also, other metal ions may be added to the metal ion solution to modify and enhance the performance of the nickel hydroxide material.
  • the metal ion solution may further comprise one or more metal ions selected from the group consisting of Al, Ba, Bi, Ca, Co, Cr, Cu, Fe, In, K, La, Li, Mg, Mn, Na, Nd, Pb, Pr, Ru, Sb, Sc, Se, Sn, Sr, Te, Ti, Y, and Zn.
  • the metal ion solution may be selected from the group consisting of a metal sulfate solution, a metal nitrate solution, and mixtures thereof.
  • the conductive material is preferably nickel particles (which may be fibers). It is noted that while the remaining discussion of the method of making the composite material is in terms of nickel particles, all types of conductive materials (as discussed hereinabove) may be used.
  • the inventors have noted the preferred aspect of adding the nickel particles to the reactor vessel by first suspending the nickel particles in the metal ion solution, especially when the metel ion solution is predominately a nickel sulfate solution. When added in this manner, nucleation and precipitation proceeded excellently.
  • the metal ion solution was also predominately a nickel sulfate solution
  • the nickel particles were added independently to the reactor vessel. This case was unsuccessful, resulting in clumped metallic nickel particles outside of the nickel hydroxide. While not wishing to be bound by theory, the inventors believe that suspending the nickel particles in the metal ion solution may be preferred due to the acidic nature of the sulfate solution.
  • a source of ammonium hydroxide is also provided.
  • the ammonium hydroxide is mixed with the metal ion solution to form an amine complex with the metal ions.
  • the amine complex is then reacted with the caustic solution to form the nickel hydroxide material.
  • the step of mixing the ammonium hydroxide solution with the metal ion solution may occur before or concurrent with the step of mixing the metal ion solution and the nickel particles.
  • the step of mixing the ammonium hydroxide solution with the metal ion solution may also occur after the step of mixing the metal ion solution and the nickel particles, but before the step of mixing the caustic solution with the suspension.
  • the step of mixing the ammonium hydroxide solution with the metal ion solution may occur concurrent with the step of mixing the caustic solution with the suspension.
  • Positive electrodes were prepared for half-cell testing by pasting a slurry of about 5% by weight of Co metal, about 5% by weight of CoO with PVA binder and the remainder active material onto foam metal substrates.

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Claims (11)

  1. Positive Verbundelektrode mit darauf pastiertem positivem Elektrodenmaterial, das Material umfassend:
    Partikeln von positivem Elektrodenmaterial, die auf die Elektrode pastiert sind;
    wobei das positive Elektrodenmaterial derart auf einem leitfähigen Metallmaterial abgeschieden ist, dass das leitfähige Metallmaterial vollständig in die Partikeln von positivem Elektrodenmaterial eingelassen ist.
  2. Positive Verbundelektrode nach Anspruch 1, wobei das leitfähige Metallmaterial Nickel oder Nickellegierung umfasst.
  3. Positive Verbundelektrode nach einem der Ansprüche 1 oder 2, wobei das leitfähige Metallmaterial zumindest ein Partikel umfasst.
  4. Positive Verbundelektrode nach einem der Ansprüche 1 bis 3, wobei das positive Elektrodenmaterial ein Nickelhydroxidmaterial umfasst.
  5. Positive Verbundelektrode nach einem der Ansprüche 1 bis 4, wobei das leitfähige Metallmaterial ein Nukleierungspartikel für das Wachsen von Nickelhydroxidkristalliten ist.
  6. Positive Verbundelektrode nach einem der Ansprüche 1 bis 5, wobei das leitfähige Metallmaterial vollständig in das Innere der Partikeln von positivem Elektrodenmaterial durch nichtmechanische Mittel eingelassen ist.
  7. Verfahren zum Erzeugen eines positiven Verbundelektrodenmaterials, das Partikeln von positivem Elektrodenmaterial und leitfähiges Metallmaterial umfasst, welches vollständig in das positive Elektrodenmaterial eingelassen ist, das Verfahren folgenden Schritt umfassend:
    Kombinieren einer Metallionenlösung, einer Lauge und des leitfähigen Metallmaterials, wodurch eine Abscheidungslösung ausgebildet wird, die das positive Verbundelektrodenmaterial enthält, und
    Abscheidung des positiven Elektrodenmaterials auf das leitfähige Metallmaterial in einem Fällbad.
  8. Verfahren nach Anspruch 7, wobei der Schritt des Kombinierens die folgenden Schritte umfasst:
    Mischen des leitfähigen Metallmaterials mit der Metallionenlösung zum Ausbilden einer ersten Kombination; und
    Mischen der ersten Kombination mit der Lauge.
  9. Verfahren nach einem der Ansprüche 7 bis 8, wobei der Schritt des Kombinierens ferner den folgenden Schritt umfasst:
    Mischen einer Ammoniumhydroxidlösung mit der Metallionenlösung zum Ausbilden einer Metallaminkomplexlösung.
  10. Verfahren nach einem der Ansprüche 7 bis 9, wobei die Metallionenlösung Metallionen von einem oder mehr Elementen umfasst, die aus der Gruppe ausgewählt sind, welche aus Nickelionen und Manganionen besteht.
  11. Verfahren nach einem der Ansprüche 7 bis 9, wobei die Metallionenlösung Nickelsulfat umfasst.
EP99939133.7A 1998-08-17 1999-08-11 Positives kompositelektrodenmaterial und verfahren zu dessen herstellung Expired - Lifetime EP1116287B1 (de)

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US09/135,460 US6177213B1 (en) 1998-08-17 1998-08-17 Composite positive electrode material and method for making same
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KR20060105055A (ko) 2006-10-09
EP1496555A3 (de) 2010-03-24
CA2339211A1 (en) 2000-02-24
NO20010772D0 (no) 2001-02-15
US6548209B2 (en) 2003-04-15
US20020146505A1 (en) 2002-10-10
NO20010772L (no) 2001-04-17
US6348285B2 (en) 2002-02-19
KR20010082174A (ko) 2001-08-29
JP5099960B2 (ja) 2012-12-19
BR9913060A (pt) 2001-05-08
WO2000010212A1 (en) 2000-02-24
MX216887B (es) 2003-10-10
EP1496555A2 (de) 2005-01-12
EP1496555B1 (de) 2013-06-19
JP2010282973A (ja) 2010-12-16
EP1116287A1 (de) 2001-07-18
AU759414B2 (en) 2003-04-17
RU2208270C2 (ru) 2003-07-10
JP5467086B2 (ja) 2014-04-09
JP2012023049A (ja) 2012-02-02
AU5347699A (en) 2000-03-06
MXPA01001580A (es) 2002-04-08
JP2002522894A (ja) 2002-07-23
US6569566B2 (en) 2003-05-27
TW432739B (en) 2001-05-01
US20010023040A1 (en) 2001-09-20
US6177213B1 (en) 2001-01-23
KR100725609B1 (ko) 2007-06-08
JP3578992B2 (ja) 2004-10-20
US20010019799A1 (en) 2001-09-06
JP2004214210A (ja) 2004-07-29

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